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BMW R 1150 GS Motorrad Repair Manual – PDF DOWNLOAD
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BMW R 1150 GS Motorrad Repair Manual – PDF DOWNLOAD
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Description
BMW R 1150 GS Motorrad Repair Manual – PDF DOWNLOAD
DESCRIPTION:
BMW R 1150 GS Motorrad Repair Manual – PDF DOWNLOAD
Introduction :
This Repair Manual will help you to perform all the main maintenance and repair work correctly and efficiently. If it is consulted regularly by workshop personnel it will form a useful addition to the theoretical and practical knowledge acquired at the BMW Training Centre. It is a contribution toward achieving even higher Service quality. A new issue of this repair manual will be published if amendments or additions (supplements) are needed. All information in both text and illustrations refers to motorcycles in standard condition or with genuine BMW accessories installed, and not to motorcycles which have been modified in any way to depart from the manufacturer’s specification.
• The Repair Manual is structured in the logical sequence of the work to be performed: Removal, Disassembling, Repair, Assembly, Installation.
• Work to be performed during an Inspection is described in Group “00”. The various inspection routines are numbered I, II, III and IV. This numbering is repeated in the work descriptions which follow, so that work can take place without interruption.
• Use of the BMW special tools needed for certain tasks is described in the work instructions.
• Use of the BMW special tools needed for certain tasks is described in the work instructions.
If the need arises, repair instructions are also issued in the form of Service Information. This information is of course incorporated into the next issue of the Repair Manual. We also recommend you to consult the detailed illustrations on the Parts microfiches as an additional source of information.
TABLE OF CONTENTS:
BMW R 1150 GS Motorrad Repair Manual – PDF DOWNLOAD
Introduction................................................................................................ 3 Maintenance schedule........................................................................................ 4 Pre-delivery check.......................................................................................... 5 Service data................................................................................................ 6 General table of contents................................................................................... 7 00 Maintenance and general instructions..................................................................... 9 Tightening torques...................................................................................... 13 Table of operating fluids............................................................................... 20 Pre-delivery check...................................................................................... 21 General view of crated motorcycle....................................................................... 21 Check the shipping crate for damage.................................................................... 22 In case of damage in Germany........................................................................ 22 In case of damage in importer markets............................................................... 22 Unpacking the motorcycle................................................................................ 22 Inspecting motorcycle for damage........................................................................ 23 Checking that delivery is complete...................................................................... 23 Installing remaining items on motorcycle............................................................... 24 Install the windscreen.............................................................................. 24 Installing sump guard............................................................................... 25 Filling and charging the battery........................................................................ 26 Disengaging and raising the fuel tank............................................................... 26 Filling and charging the battery.................................................................... 26 Checking engine oil when engine is cold, topping up if necessary........................................ 27 Checking headlight beam angle, adjusting if necessary................................................... 28 Checking tightness of rear wheel studs.................................................................. 28 Checking tyre pressures................................................................................. 28 Attaching adhesive label................................................................................ 28 Final inspection and function check..................................................................... 29 Final cleaning.......................................................................................... 29 Handing over the motorcycle............................................................................. 29 Maintenance............................................................................................. 30 Key to maintenance intervals............................................................................ 30 Reading out MoDiTeC fault memory........................................................................ 30 Changing engine oil, replacing oil filter element....................................................... 30 Changing oil in gearbox................................................................................. 31 Changing the oil in the rear wheel drive................................................................ 31 Replacing fuel filter................................................................................... 32 Checking battery fluid level and topping up if necessary; cleaning and greasing the battery posts...... 34 Replacing intake air filter element..................................................................... 34 Replacing Poly-V belt................................................................................... 35 Checking brake system for correct operation and freedom from leaks; repairing/replacing if necessary.... 36 Checking brake fluid level.............................................................................. 36 Front brake......................................................................................... 36 Rear brake.......................................................................................... 36 Checking brake pads and discs for wear/replacing........................................................ 37 Checking front brake pad wear....................................................................... 37 Checking rear brake pad wear........................................................................ 37 Checking brake disc wear............................................................................ 37 Replacing brake pads, front brake................................................................... 38 Replacing brake pads, rear brake.................................................................... 38 Changing brake fluid and bleeding brake system.......................................................... 39 Bleeding front brake circuit/changing brake fluid................................................... 39 Bleeding rear brake circuit/changing brake fluid.................................................... 41 Checking clutch operating fluid level................................................................... 42 Changing the clutch fluid............................................................................... 42 Checking tightness of rear wheel studs.................................................................. 43 Checking rear wheel bearing play by tilting wheel....................................................... 43 Checking swinging arm bearings, adjusting if necessary................................................. 43 Greasing the side stand pivot........................................................................... 44 Checking function of side stand contact switch.......................................................... 44 Checking/replacing spark plugs.......................................................................... 44 Tightening cylinder heads............................................................................... 45 Checking/adjusting valve clearances.................................................................... 45 Checking freedom of throttle cable, checking for chaffing and kinks, replacing if necessary Check....... 46 Final inspection with road safety and functional check.................................................. 47 11 Engine................................................................................................... 48 Cutaway drawing of engine............................................................................... 59 Lubricating-oil circuit................................................................................. 60 Cooling-oil circuit..................................................................................... 61 Removing engine......................................................................................... 62 Disassembling engine.................................................................................... 66 Removing cylinder head cover........................................................................ 67 Locking the engine at TDC........................................................................... 68 Removing and installing chain tensioner............................................................ 69 Remove valve gear carrier........................................................................... 70 Disassembling/assembling valve gear carrier......................................................... 71 Removing cylinder head.............................................................................. 73 Disassembling, checking, repairing and reassembling cylinder head................................... 74 Removing cylinder................................................................................... 78 Removing and disassembling piston................................................................... 78 Checking pistons and cylinders...................................................................... 79 Assembling pistons.................................................................................. 79 Removing and installing conrod...................................................................... 80 Removing and installing alternator mount cover with engine installed................................ 81 Removing alternator mount cover..................................................................... 81 Replacing radial shaft seal in alternator mount cover............................................... 81 Removing auxiliary shaft drive...................................................................... 82 Removing oil pump................................................................................... 83 Removing radial shaft seal from crankshaft with engine installed................................... 84 Disassembling crankcase............................................................................. 85 Removing crankshaft, auxiliary shaft and timing chain tensioning and slide rails.................... 87 Removing and installing oil intake strainers........................................................ 88 Replacing oil level sight glass..................................................................... 88 Removing and installing oil thermostat.............................................................. 88 Removing conrods.................................................................................... 88 Checking conrods.................................................................................... 88 Measuring crankshaft bearing play................................................................... 89 Measuring big end bearing play...................................................................... 91 Assembling engine....................................................................................... 92 Installing conrods.................................................................................. 92 Installing crankshaft............................................................................... 93 Installing timing chain tensioning and slide rails.................................................. 93 Installing auxiliary shaft/timing chains............................................................ 93 Assembling engine block............................................................................. 94 Installing radial shaft seals on crankshaft........................................................ 97 Installing clutch housing........................................................................... 98 Installing oil pump................................................................................. 99 Installing auxiliary shaft drive....................................................................100 Installing piston...................................................................................101 Installing cylinder.................................................................................102 Installing cylinder head............................................................................103 Adjusting valve clearances..........................................................................104 Installing right cylinder head......................................................................105 Installing left cylinder head.......................................................................106 Installing alternator mount cover...................................................................108 Installing magnetic gate/belt pulley................................................................108 Installing alternator...............................................................................110 Installing engine.......................................................................................111 12 Engine electrics.........................................................................................112 Removing and installing coil and ignition lead..........................................................116 Checking ignition coil resistance...................................................................116 Removing and installing alternator......................................................................117 Disassembling/assembling alternator....................................................................118 Checking alternator.................................................................................118 Checking armature for short to ground (earth).......................................................118 Disassembling/assembling alternator (Option 50 A)......................................................119 Checking alternator.................................................................................119 Checking armature for short to ground (earth).......................................................119 Removing and installing starter motor...................................................................120 Disassembling/assembling starter motor..................................................................121 Replacing carbon brushes............................................................................121 Checking starter motor..............................................................................121 Checking starter relay..............................................................................121 Removing and installing magnetic gate...................................................................122 Timing the ignition.................................................................................123 13 Fuel preparation and control.............................................................................124 Removing and installing air filter housing..............................................................128 Removing and installing trottle- valve stub pipe.....................................................129 Removing and installing throttle- valve potentiometer...................................................130 Removing and installing Motronic control unit...........................................................130 16 Fuel tank and lines......................................................................................131 Removing and installing fuel tank.......................................................................135 Removing and installing roll-over valve.................................................................136 Removing and installing fuel filter, fuel pump and fuel level sensor....................................137 Removing and installing fuel filter.................................................................137 Removing and installing fuel pump and fuel level sensor.............................................137 Removing and installing fuel distributor and pressure regulator........................................138 18 Exhaust system...........................................................................................139 Removing and installing exhaust system..................................................................141 Removing and installing silencer and front silencer.................................................141 Removing and installing exhaust manifolds..........................................................142 21 Clutch...................................................................................................143 Removing and installing clutch..........................................................................147 Removing clutch.....................................................................................147 Installing clutch...................................................................................149 Removing and installing clutch hydraulic line...........................................................150 Removing and installing clutch slave cylinder...........................................................150 Filling/bleeding clutch line............................................................................151 23 Transmission.............................................................................................152 Gearbox - sectional drawing.............................................................................156 Removing and installing gear-shift lever................................................................158 Removing/installing gearbox.............................................................................158 Replacing the shaft sealing rings in the gearbox housing and gearbox cover..........................160 Disassembling gearbox...................................................................................162 Removing gearbox housing............................................................................162 Removing selector drum..............................................................................163 Disassembling/assembling selector shaft.............................................................163 Removing gearbox shafts.............................................................................164 Replacing grooved ball bearings of intermediate shaft...............................................164 Disassembling/assembling input shaft................................................................165 Disassembling/reassembling output shaft.............................................................167 Checking endplay....................................................................................169 Checking/adjusting fully assembled length of gearbox shafts and selector drum.......................170 Shimming selector shaft.............................................................................174 Assembling gearbox......................................................................................174 Installing input, output and intermediate shafts...................................................175 Installing selector shaft...........................................................................176 Installing selector drum............................................................................176 Installing gearbox housing..........................................................................177 31 Front forks..............................................................................................179 Removing and installing telescopic fork.................................................................183 Removing and installing telescopic fork without fork bridge.........................................183 Removing and installing fork bridge.................................................................184 Removing and installing slider tube bridge..........................................................186 Checking friction at ball joint/angular- contact ball bearing.......................................186 Disassembling/assembling telescopic fork...............................................................187 Disassembling telescopic fork.......................................................................187 Assembling telescopic fork..........................................................................187 Measuring telescopic fork...............................................................................188 Removing and installing leading link....................................................................189 Disassembling/assembling leading link...................................................................189 Removing and installing front spring strut..............................................................189 32 Steering.................................................................................................190 Removing and installing left handlebar fitting.........................................................194 Removing and installing right handlebar fitting........................................................195 Removing and installing brake piston in handlebar fitting...............................................196 Removing and installing clutch piston in handlebar fitting..............................................197 Checking and adjusting operating clearance at front brake/clutch levers.............................198 Removing and installing handlebar.......................................................................199 Removing and installing Bowden- cable divider, Bowden cable for throttle actuation and starting.......200 Disassembling Bowden-cable divider.....................................................................201 33 Rear wheel drive.........................................................................................202 Removing, disassembling, reassembling and installing rear wheel drive..................................206 Removing rear wheel drive...........................................................................206 Removing and installing taper roller bearing in rear wheel drive....................................206 Removing input bevel pinion.........................................................................207 Disassembling input bevel pinion....................................................................208 Assembling input bevel pinion.......................................................................209 Installing input bevel pinion.......................................................................210 Removing and disassembling crown wheel..............................................................212 Assembling and installing crown wheel...............................................................213 Shimming input bevel pinion and crown wheel.........................................................214 Checking tooth contact pattern......................................................................215 Checking and adjusting backlash.....................................................................216 Shimming housing cover..............................................................................217 Installing housing cover............................................................................217 Installing sliding element..........................................................................217 Installing rear wheel drive.........................................................................218 Removing and installing spring strut...................................................................219 Removing and installing rear swinging arm..............................................................220 Removing rear swinging arm..........................................................................220 Removing and installing taper roller bearing........................................................221 Removing and installing flexible gaiter.............................................................221 Removing drive shaft................................................................................221 Installing drive shaft..............................................................................221 Installing rear swinging arm........................................................................222 34 Brakes...................................................................................................223 Removing and installing front brake caliper.............................................................226 Disassembling and assembling front brake caliper........................................................227 Removing and installing filler adapter..............................................................228 Removing and installing rear brake caliper..............................................................229 Disassembling and assembling rear brake caliper.........................................................230 Removing and installing front brake disc................................................................231 Removing and installing rear brake disc (mounted on rear-wheel hub)....................................232 Removing and installing front ABS sensor................................................................233 ABS sensor gap, front: adjusting........................................................................234 Marking sensor ring.................................................................................234 Checking and adjusting sensor gap...................................................................234 Removing and installing rear ABS sensor.................................................................235 Adjusting rear ABS sensor gap...........................................................................236 Marking sensor wheel................................................................................236 Checking and adjusting sensor gap...................................................................236 Removing and installing rear brake master cylinder......................................................237 Checking and adjusting play of piston rod...........................................................238 Removing and installing footbrake lever.................................................................238 Removing and installing ABS unit........................................................................239 Removing the ABS unit...............................................................................239 Installing the ABS unit.............................................................................240 Removing and installing ABS relay and relay socket......................................................240 Removing ABS relay..................................................................................240 Installing the ABS relay............................................................................241 Removing ABS relay socket...........................................................................241 Installing the ABS relay base.......................................................................242 Removing and installing brake line (withABS)...........................................................243 Removing and installing front brake line............................................................243 Removing and installing rear brake line.............................................................244 36 Wheels and tyres.........................................................................................245 Removing and installing front wheel.....................................................................249 Removing front wheel................................................................................249 Installing the front wheel..........................................................................249 Removing and installing wheel bearings.............................................................250 Removing/installing rear wheel..........................................................................252 Removing rear wheel.................................................................................252 Installing rear wheel...............................................................................252 Static balancing of front wheel/rear wheel..............................................................253 Checking front/rear wheel rim for runout................................................................254 Removing/installing spokes..............................................................................255 Centering the wheel rim.................................................................................255 Centering lateral runout............................................................................255 46 Frame....................................................................................................256 Overall view, frame.....................................................................................260 Removing and installing main (centre) stand............................................................261 Removing and installing side stand......................................................................262 Removing and installing front mudguard.................................................................263 Removing and installing bottom section of mudguard.................................................263 Removing and installing top section of mudguard.....................................................264 Removing and installing windscreen......................................................................265 Removing and installing fairing bracket.................................................................266 Removing and installing luggage rack....................................................................267 Removing and installing number- plate carrier..........................................................268 Removing/installing rear mudguard.......................................................................269 Removing and installing rear footrest plate............................................................270 Removing and installing front footrest plate...........................................................271 Removing and installing right footrest plate........................................................271 Removing and installing left footrest plate.........................................................272 Removing/installing frame...............................................................................273 Removing and installing frame tail section..............................................................274 Checking running gear...................................................................................275 Measuring wheel track offset........................................................................275 Measuring the leading link..........................................................................277 51 Equipment................................................................................................278 Removing and installing ignition switch/steering lock...................................................280 Removing and installing ignition/light switch.......................................................280 Removing and installing lock barrel.................................................................280 Removing and installing lock barrel for fuel tank filler cap............................................281 Removing and installing seat lock.......................................................................282 Removing and installing lock barrel.................................................................282 Removing and installing helmet lock.....................................................................282 52 Seat.....................................................................................................283 Disassembling/assembling seat...........................................................................285 61 General electrical equipment.............................................................................286 Removing and installing central electrical equipment box................................................290 Disassembling/assembling central electrical equipment box...............................................290 Relay positions/fuse assignments (central electrical equipment box).....................................291 Wiring-harness routing, frame [ABS].....................................................................292 Wiring-harness routing/connection in central electrical equipment box...............................293 Wiring-harness routing/central electrical equipment box/output.....................................294 Wiring-harness routing View from left...............................................................295 Wiring-harness routing View from right..............................................................298 Removing and installing battery holder..................................................................302 62 Instruments..............................................................................................303 Removing and installing instrument panel................................................................306 63 Lights...................................................................................................307 Removing and installing headlight.......................................................................310 Removing and installing front indicators...............................................................311
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